300, 300C & Magnum 2006-2008, Charger 2006-2008

Brake Disc (Rotor)

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Removal & Installation



Except SRT8
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel and tire assemblies.
    NOTE
    In some cases, it may be necessary to retract caliper piston in its bore a small amount in order to provide sufficient clearance between shoes and rotor to easily remove caliper from knuckle. This can usually be accomplished before mounting bolts are removed, by grasping rear of caliper and pulling outward working with guide pins, thus retracting piston. Never push on piston directly as it may get damaged.

  4.  
  5. For AWD models, remove the caliper, by performing the following:
    1. Remove the two bolts (1) securing disc brake caliper and adapter (2) to knuckle (3).
    2.  
    3. Remove the disc brake caliper and adapter (2) from knuckle (3) as an assembly. Hang assembly out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this.

      Click image to see an enlarged view

      Fig. Remove the caliper-AWD models

    4.  

  6.  
  7. For RWD models, remove the caliper by performing the following:
    1. Remove the two bolts (2) securing disc brake caliper and adapter (3) to knuckle (1).
    2.  
    3. Remove the disc brake caliper and adapter (3) from knuckle (1) as an assembly. Hang assembly out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this.

      Click image to see an enlarged view

      Fig. Removing the caliper-RWD models

    4.  

  8.  
  9. Remove any clips retaining the brake rotor to the wheel studs.
  10.  
  11. Slide the rotor off the hub and bearing.
  12.  

To install:

  1. Clean the hub face to remove any dirt or corrosion where rotor mounts.
  2.  
  3. Install the brake rotor over the studs on hub and bearing.
  4.  
  5. For AWD models, perform the following:
    1. Install the disc brake caliper and adapter assembly over brake rotor.
    2.  
    3. Install the mounting bolts securing caliper adapter to knuckle, and tighten to 70 ft. lbs. (95 Nm).
    4.  

  6.  
  7. For RWD models, perform the following:
    1. Install the disc brake caliper and adapter assembly over brake rotor.
    2.  
    3. Install the mounting bolts securing caliper adapter to the knuckle and tighten to 70 ft. lbs. (95 Nm).
    4.  

  8.  
  9. Install tire and wheel assembly. Tighten the lug nuts to 110 ft. lbs. (150 Nm).
  10.  
  11. Lower vehicle.
  12.  
  13. Pump brake pedal several times to set pads to caliper and brake rotor.
  14.  
  15. Check and adjust brake fluid level in reservoir.
  16.  
  17. Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake shoes.
    WARNING
    If NEW brake rotors or pads have been installed, keep in mind that braking effectiveness might be somewhat reduced during the first brake applications following installation.


    CAUTION
    A burnish procedure must be performed anytime NEW brake pads or rotors are installed on a vehicle equipped with the Police Package. This procedure is particularly important in situations where high speed pursuit is a possibility. It is recommended that the procedure be performed by the Police agency operating the vehicle so it can be performed in a safe controlled environment. This information is covered in the Police Package Owner-s Manual Supplement which was supplied when the vehicle was originally delivered.

  18.  
  19. Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake shoes. If the vehicle is equipped with the Police Package, a burnish procedure must be followed (Refer to preceding Caution.
  20.  

SRT8
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel and tire assemblies.
    WARNING
    When pushing pistons back into caliper bores, use only a trim stick as shown or other suitable soft tool. Never use a screwdriver or other metal pry bar due to potential damage to braking surface of rotor, caliper, pistons or dust boots.

  4.  
  5. Place a trim stick (4) between brake pad (2) and outer edge of rotor (3).
  6.  
  7. Using the trim stick, slowly apply pressure against brake pad (2) until both pistons (on that side of caliper) are completely bottomed in bores of caliper half.
    NOTE
    Repeat the above procedure to opposite brake pad (1) and pistons as necessary.



    Click image to see an enlarged view

    Fig. The proper way to retract the piston on SRT-8 models

  8.  
  9. Remove caliper mounting bolts (1).
  10.  
  11. Remove brake caliper (2) with pads from knuckle (8) and brake rotor (3). Hang assembly out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this.
  12.  
  13. Remove any clips (4) retaining brake rotor (3) to wheel studs.
  14.  
  15. Slide brake rotor (3) off hub and bearing (7).

    Click image to see an enlarged view

    Fig. Exploded view of rotor removal-SRT-8 models

  16.  

To install:

  1. Clean the hub face to remove any dirt or corrosion where rotor mounts.
  2.  
  3. Install the brake rotor (3) over studs on hub and bearing (7).
  4.  
  5. Slide the caliper with pads (2) over brake rotor (3) and align with knuckle (8).
  6.  
  7. Install the caliper mounting bolts (1) and tighten to 140 ft. lbs. (190 Nm).
  8.  
  9. Install tire and wheel assembly. Tighten the lug nuts to 110 ft. lbs. (150 Nm).
  10.  
  11. Lower vehicle.
  12.  
  13. Pump brake pedal several times to set pads to caliper and brake rotor.
  14.  
  15. Check and adjust brake fluid level in reservoir.
    WARNING
    If NEW brake rotors or pads have been installed, keep in mind that braking effectiveness might be somewhat reduced during the first brake applications following installation.

  16.  
  17. Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake pads. If NEW brake pads are installed, they need to be properly burnished
  18.  

 
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